General Strategies in Developing Alloy Steel Fuzzy Model for Machinability Data Selection of Turning Process

In this paper, several fuzzy models have been proposed for machinability data selection of turning process of alloy steel. The selection of the machinability data is a crucial task, and normally done by the skilled machinists. Thus, fuzzy models-have been suggested for predicting the optimum machinability data, which are cutting speed and feed rate. These fuzzy models are developed based on the relationship of two-input (material hardness and depth of cut) and two-utput (cutting speed and feed rate). A few general strategies in developing fuzzy models are presented and discussed in this paper. Generally, there are three different strategies that are suggested in this paper. The objective of implementing these strategies is to simplify the process of fuzzy model development. The predicted cutting speed and feed rate are compared with the data obtained from the Machining Data Handbook (Metcut Research Associate 1980) and a good correlation has been shown throughout the comparison

A Survey of Automated Process Planning Approaches in Machining

Global industrial trend is shifting towards next industrial revolution Industry 4.0. It is becoming increasingly important for modern manufacturing industries to develop a Computer Integrated Manufacturing (CIM) system by integrating the various operational and information processing functions in design and manufacturing. In spite of being active in research for almost four decades, it is clear that new functionalities are needed to integrate and realize a completely optimal process planning which can be fully compliant towards Smart Factory. In order to develop a CIM system, Computer Aided Process Planning (CAPP) plays a key role and therefore it has been the focus of many researchers. In order to gain insight into the current state-of-the-art of CAPP methodologies, 96 research papers have been reviewed. Subsequent sections discuss the different CAPP approaches adopted by researchers to automate different process planning tasks. This paper aims at addressing the key approaches involved and future directions towards Smart Manufacturing

Selection of Optimum Cutting Speed In End Milling Process Using Fuzzy Logic

The machining process shows ambiguous behavior and often cannot be linearly extrapolated in a wide range. It cannot be modeled effectively using theories and equations. The classical method for selection of machining parameters, such as cutting speed  is based on data from machining hand books for machining parameters or on the experience of the operator or CNC programmer. The parameters chosen in most situations are highly conservative to protect over- matching errors from tool failures, such as deflection, breakage, etc.  In this paper,  a model to find the optimum cutting speed for end milling operation was built using Fuzzy Logic, this model is user-friendly and compatible with the automation concept of a flexible and computer integrated manufacturing systems. It allows the operator, even unskilled, to find the optimal cutting speed for an efficient machining process that can lead to an improvement of product quality, increase production rates and thus reducing product cost and total manufacturing costs. The developed fuzzy logic model showed a good prediction to select the optimum cutting speed , with a mean absolute error of around 4.5% from the optimum machining parameters in the Machining Data Handbook. Keywords: Fuzzy Logic, End Milling Process, CNC, FL, Optimum Cutting Speed Selection

Machinability assessment and tool selection for milling.

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Technical feasibility analysis of utilizing special purpose machine tools

Special purpose machine tools (SPMs) are primarily used for performing drilling-related operations and are widely used in mass production including automotive component manufacturing. Utilization of SPM is considerably widespread; however, this technology is relatively new and expensive. The important problems facing manufacturing industries wishing to utilize this technology is feasibility analysis to decide whether a SPM can be utilised for production of the given part and if it is feasible which SPM components would be appropriate. Since the cost of utilizing SPM is high, feasibility analysis must be performed before any investment on detailed design. This paper proposes a technical feasibility analysis method which assists in deciding whether SPM is applicable for machining a given part to achieve the highest productivity. The method is based on the framework which consists of relations between the desired part properties to the characteristics of the SPM components. These relations are captured as rules and constraints in an intelligent system which is implemented in Visual Basic. Applying the proposed method to a number of industrial parts shows that it is a very useful tool in deciding when SPMs should be utilized

The implication of rapid technologies on the design process

This dissertation focuses on the challenges of design and additive manufacturing (AM). It considers the challenges that such a freeform manufacturing process can have on design freedom. Much of the current literature is focused on this design freedom only as a positive, and work to improve design-for-AM, and how to better exploit the technology. On the contrary, this work looks at how that design freedom can be a challenge if and when a move from AM to a more conventional process is needed. The work is broken into three studies related to the implication of rapid technologies on the design process. Firstly, a user study to examine the effect of AM on design fixation was implemented using two groups, a Design for Conventional Manufacturing (DFCM) group and a Design for Additive Manufacturing group (DFAM). It was found that designers who trained on AM knowledge (DFAM group) experienced a design fixation on non-producible features and produced harder to conventionally manufacture designs, even when asked to modify designs for conventional manufacturing. This brings to light the negative effect of AM knowledge on designers and necessitates treatment methods. Therefore, the second part of this work focused on treating the negative effects of AM knowledge on designer skills. Mainly, a user study investigated the use of Design for Manufacturing (DFM)-based software in mitigating design fixation on non-producible features. The 3D feedback of the DFM software helped to reduce design fixation on non-producible features and improved the machinability of modified designs. The DFM feedback helped designers by highlighting areas in the design that could have machinability problems, however, it did not provide designers with a suggestion on how to modify and migrate their designs from AM to Conventional processes. Thus, the third part of this dissertation proposed a method that can provide a designer with suggestions to modify a design and allow its migration from AM to conventional processes. The method determines best cut lines for dissecting a design into pieces such that the surfaces of problematic features become more machinable. The method was tested, and results showed that the method can dissect a design into components that have better machinability on average than the original design. Overall, this work suggests the use DFM software and a dissection method for treating the design fixation related to AM and for facilitating the migration of designs from additive to conventional manufacturing. This work could be applied to manufacturing industries, particularly for AM parts that are slated for mass production which will require migration to conventional methods

Computer Architecture in Industrial, Biomechanical and Biomedical Engineering

This book aims to provide state-of-the-art information on computer architecture and simulation in industry, engineering, and clinical scenarios. Accepted submissions are high in scientific value and provide a significant contribution to computer architecture. Each submission expands upon novel and innovative research where the methods, analysis, and conclusions are robust and of the highest standard. This book is a valuable resource for researchers, students, non-governmental organizations, and key decision-makers involved in earthquake disaster management systems at the national, regional, and local levels

Analysis of the Integration of DFM Techniques and Effective Machining Parameter Selection in Metal Parts Manufacturing

This dissertation investigates the minimization of part design with self-locating features. The research focuses primarily on self-fastening characteristics, standardization of parts, and minimal use of fasteners. Further, the present research studies the design for base parts in the construction of a moving joint system, in order to locate potential part and system design improvements. This process may then be extended to industrial applications in the manufacturing industry. Relatively little work to date has examined the significance of Design for Manufacturing Techniques (DFMT), with their inherent machine element systems and machining parameters to investigate which DFMT has the most influence on cost reduction and increasing throughput, and under which circumstances. As such, this dissertation analyzes the inter-operational and synergistic elements of the DFMT, machine element systems, and machining parameters. The parametric specifications for the DFMT are examined and integrated with the cost and productivity-related information. In sum, this research applies DFMT to product design. The trade-off between cost of manufacturing and productivity in terms of DFM alternatives was subject to preliminary model development and sensitivity analysis. For each DFMT and associated machine element systems and Machining parameters, process planning was used effectively with computer-aided tools to enhance the evaluation impact of the dialogue between the design and manufacturing functions. Expert systems and systematic algorithms are inherently incorporated into the software tools used herein. Generative process planning software is used to measure and analyze sensitivity in plan effectiveness, particularly where material property attributes are changed. The shift that occurs according to process plan attributes is explored. These attributes are presented by manufacturing cost and production rate with respect to variations in specific material properties. The research analyzes four DFMT: Modifying the selection of raw material Modifying quality Modifying geometry Modifying the selection of process/es In terms of organizing and evaluating the work, a systematic algorithm was developed, discussed, and tested in this dissertation. This algorithm has sequenced elements to investigate and analyze each DFMT. This analysis identifies several potential process plans, from which the plan with the lowest projected cost and highest production rate is selected and constructed. The developed process plans illustrate the importance of alternative DFMT, without impacting product functionality. Each process plan attempts to decrease production cost, maintain quality, and increase throughput. The results of these plans show their respective effectiveness in relation to part utilization, process, and system-level parameters (such as surface finish, tolerance, heat treated condition of the material, geometry, material hardness, melting point, production quantity, cutting tools, cutting fluids, cutting conditions, and machine tools). The criteria for effectiveness include machining cost, tool cost, and throughput. From this data, the current study determines the most appropriate DFMT and examines underlying alternate machine element systems and machining parameters for each process plan. The effects of DFMT and inherent use of varying machine element systems and machining parameters on cost and productivity-based objectives are also examined. This enables exploration of the selected DFMT choice, according to effective cost reduction and production rate improvement for varying product design. The modified process plan is then compared to the original process plan to highlight areas of improvement. In this comparison, the results of DFMT analysis show significant influence on cost reduction and production rates. These findings suggest that further beneficial outcomes and variety might be obtained by applying this algorithm

Decision-making processes on sustainable packaging options in the European food sector

Food packaging improves shelf life and allows longer transportation distances in global food supply chains, but it is also responsible for huge volumes of waste. The transition to sustainable packaging by food companies has often been slow and inconsistent. How decisions on (sustainable) packaging are made within companies in the food sector remains mostly opaque to research. To explore the decision-making process and identify barriers for cleaner, more resource efficient food packaging, we carried out 17 interviews in four European countries across different food sectors using the theoretical decision-making process of Nutt (1984) as an analytical framework. Through qualitative content analysis, we found that decision-making processes often lack structure and extend over long stretches of time. Frequently, they are initiated in response to packaging material manufacturers or suppliers. Switching to more sustainable packaging often implies costly investments into new machinery. Economic sustainability takes precedence over ecological sustainability. We recommend companies move to life-cycle cost models for packaging decisions, commit to mono- and other recyclable materials, and establish structured decision-making processes with clear cut-off criteria so as to streamline implementation decisions. Our results further support a call for progressive legislation towards a circular economy in the packaging sector.info:eu-repo/semantics/publishedVersio